Device and method for manufacturing artificial solid bone

Abstract

A device and method for manufacturing artificial solid bone by metal 3D printing technology comprises: a metal 3D printing technology is used and preferably with Co—Cr alloy and laser sintering to form a solid bone with a specific change in shape and density; a synchronous cutting operation performed on approximately 80% of the preferred surface of the solid bone while the metal 3D printer unit is printing the solid bone, to make the solid bone have the following surface roughness: Ry<1˜2 μm or less; and a synchronous polishing operation performed on at least one joint surface of the solid bone, to make the joint surface have the following surface roughness: Class A4=Ra0.063 μm or less.

1 . The present disclosure relates to a method for manufacturing artificial solid bone, which comprises:
 a metal 3D printing technology is used and preferably with Co—Cr alloy and direct metal laser sintering to form a solid bone with a specific shape and density;   a synchronous cutting operation performed on approximately 80% of the surface of the solid bone while the metal 3D printer unit is printing the solid bone, to make the solid bone have the following surface roughness: Ry<1˜2 μm; and   a synchronous polishing operation performed on at least one contact surface of the solid bone, to make the joint surface have the following surface roughness: Class A4=Ra0.063 μm or less.   
     
     
         2 . The method for manufacturing artificial solid bone according to  claim 1 , wherein:
 the solid bone printed and formed by the metal 3D printer unit includes an extension part formed at the top and/or bottom of the solid bone, which facilitates subsequent processing operations of the solid bone, the extension part is preferably a cylinder part, comprising a cylinder part with a diameter of 8 mm and a length of 8˜10 mm. An axis of the cylinder part is parallel and/or coincident with a center axis of the solid bone; and/or the cylinder part is configured to couple with the processing machine for subsequent processing operations to carry out the required processing operations.   
     
     
         3 . The method for manufacturing artificial solid bone according to  claim 1 , wherein:
 the solid bone comprises a first density part and a second density part whose density is lower than the first density part, wherein the first density part may preferably achieve a density higher than the second density part by performing additional sintering operations; and/or the second density part is preferably configured to have a grid structure to achieve a density lower than the first density part; and/or the first density part is preferably located peripherally to the second density part; the first density part preferably has a relative density of 99.5% or more and the second density part preferably has a relative density of 90% or more.   
     
     
         4 . The method for manufacturing artificial solid bone according to  claim 1 , wherein:
 the solid bone is a foot-ankle bone; and/or the Co—Cr alloy includes Co—Cr—Mo and/or Co—Cr—W—Ni.   
     
     
         5 . The method for manufacturing artificial solid bone according to  claim 1 , wherein: the solid bone is manufactured by a manufacturing device, and the manufacturing device comprises:
 a metal 3D printer unit that is preferably configured to sinter with a Co—Cr alloy and a direct metal laser to form a solid bone with a specific shape and density;   a cutting unit operationally connected to the metal 3D printer unit performs a synchronous cutting operation on approximately 80% of the preferred surface of the solid bone while the metal 3D printer unit is printing the solid bone, to make the solid bone have the following surface roughness: Ry<1˜2 μm;   a polishing unit operationally connected to the cutting unit performs a synchronous polishing operation on at least one joint surface of the solid bone, to make the joint surface have the following surface roughness: Class A4=Ra0.063 μm or less.   
     
     
         6 . The method for manufacturing artificial solid bone according to  claim 5 , wherein:
 the solid bone printed and formed by the metal 3D printer unit includes an extension part formed at the top and/or bottom of the solid bone, which facilitates subsequent processing operations of the solid bone, the extension part is preferably a cylinder part, comprising a cylinder part with a diameter of 8 mm and a length of 8˜10 mm. An axis of the cylinder part is parallel and/or coincident with a center axis of the solid bone; and/or the cylinder part is configured to couple with the cutting unit and/or the polishing unit for processing operations.   
     
     
         7 . The method according to  claim 5 , wherein:
 the solid bone comprises a first density part and a second density part whose density is lower than the first density part, wherein the first density part may preferably achieve a density higher than the second density part by performing additional sintering operations; and/or the second density part is preferably configured to have a grid structure to achieve a density lower than the first density part; and/or the first density part is preferably located peripherally to the second density part; the first density part preferably has a relative density of 99.5% or more and the second density part preferably has a relative density of 90% or more.   
     
     
         8 . The method for manufacturing artificial solid bone according to  claim 5 , wherein:
 the solid bone formed by the metal 3D printer unit is a foot-ankle bone; and/or the Co—Cr alloy includes Co—Cr—Mo and/or Co—Cr—W—Ni.